Mattress and process of manufacture



June 6, 1933.` s KARPEN ET AL 1,913,081

MATTRESS AND PROCESS 0F MANUFACTURE Fi1ed-ApI`il .18, 1931 2 Sheets-.Sheet l ,Y y'f/ f Jurv1e6,` 1933. s. iKARPEN ET AL MATTRESS AND PROCESS OF MANUFACTURE Filed April 18, 1931 ZSheets-Sheet 2 IIJ l ummlwmnllh .um Mmm... W..

Patented June 6, 1933- UNITED STATES PATENT OFFICE SOLOMON KARPEN, F CHICAGO, ILLINOIS, AND vFRANK KASPAB, 0F HUNTINGTON PARK, CALIFORNIA, ASSIGNOBS TO S. KARfEN BROS., OF CHICAGO, ILLINOIS, A

CORPORATION 0F WEST VIRGINIA IATIRES AND vPROCESS 0F IANUFCTUBE Application led 'April 18, 1931. Serial No. 531,166.

ing material; the filling is stuffed or intro duced into the casin thus formed, `the openving being closed a er the introduction of the filling; an edgero1l is formed by stitching through the corner rtions of the casing and the inter sed ling material; and

top and bottom nish-fabrics are then applied to the stuifed casing having the previously formed edge-roll rtions, and the edge-portions of said fabrics are then sewed to the edge-portions of the finish-fabric ofthe boxing at the corners ofthe mattress,

thus completing the mattress.

The filling material may be introduced into the casing through an open end of the casing; or the filling may be introduced through an open top side of the casing..

Where the factory is equipped with a suitable machine for stuilin the filling through the end of the casing, t is method of introducing the lilling is preferred.

rlhe invention is shown in the accompanying drawings, in which- Figure 1 is a broken vertical longitudinal Isectional view of a mattress casing comprising a uilted boxing and top and bottom 40 lining-s eets secured to the marginal portions of the boxing, one end of the casing being left open to permit stuing; Fig. 2, a

broken vertical sectional view showing such a casing in stuffed condition; Fig. 3, a broken view, partly in section and partly in elevation, illustrating the manner in which edge-rolls are formed at the corner portions of the mattress before the top and bottom finish-fabrics are applied; Fig. 4, a similar view showing the mattress after the top and comprisin bottom iinishfabrics have been applied and' sewed to the marginal portions of the boxing Fig. 5, a broken transverse vertical section illustrating a modicationin which the casing is stuied through an open side, the casing a quilted boxing and top and bottom lining-fabrics; Fig. 6, a broken view, partly in section and partly in elevation, illustrating a finished mattress, according to a slight modification wherein a modified form of boxing is employed; and Fig. 7, a similar view, showing another modification of the boxing. l

In the construction. illustrated in Figs. 1--4, Al desi ates a mattress casing com- 65 prising a quilted boxing 1 and top and bot` tom lining-sheets 2 having their marginal portions secured to the mar nal portions of the boxing by stitches 3; A A designate top and bottom finish-fabrics applied, as a final step, in finishing the mattress; andB designates a filling which comprises an inner spring structure B and layers B2 of filling material over the spring structure.

In the illustration given in Figs. 1-4, the boxing 1 comprises sim ly a strip of finishfabric 1* and a layer oi) cotton 1".

The boxing is prepared by sewing the layer of cotton and the fabric together by longitudinal lines oi stitching 1 (Fi 4) and vertical lines of stitching 1d, a apted toV give the appearance of vertical Hutings.

' It has been found unnecessary to employ a lining-fabric in conjunction with the hnish-fahric in forming the honing. In other Words, the layer oi cotton and the -hnishfabric may simply be quilted together by a sewing or einhroidering operation.

Assuming a casing or sack to have been formed in the manner illustrated in Fig. 1, the filling B is introduced through the open end of the casing, preferably by means of a stuffing machine. Thereafter, the end-portions of the boxing corresponding with the open end of the casing are sewed to the eorl responding end-margins of the top and bottom fabrics 2.

This leaves the structure in the condition shown in Fig. 2,. where the inner spring structure B is shown as comprising a series of fabric-cells 4 and upholstery springs 4 contained in the fabric-cells.

It is preferred to include with the filling edge layers of cottton 5 which are interposed between the quilted boxing and the adjacent rows of springs.

After the stuffing operation, the corner portions of the mattress are operated upon to form edge-rolls. This is done by stitching through the corner portions of the mat-- tress, as indicated in Figs. 3 and 4. This stitching rovides ties 6 which form the edge-rolls Where a design is worked into the boxing in the quilting operation, it is preferred to have the exposed loops of the ties 6 register advantageously with points of intersection, apices, or the like, of the quilting of the boxing. Thus, in Fig. 4, the exposed loops of the ties 6 are shown registering with the points of intersection of the vertical lines of stitches 1d and the horizontal line of stitches 1.

After the edge-rolls have been formed as shown in Fig. 3, in which operations the edge-roll forming stitches pass wholly through the boxing, the top and bottom iinish fabrics A are placed in position and sewed to the edge-portions of the boxing. In this operation, which may be performed by means of a suitable sewing machine, a corner tape 8 may be applied. The stitchings at the corners of the mattress are designated 88.

It will be observed that while it is desirable to use care in properly spacing the exposed loops of the ties 6, it is unnecessary to use any particular care where the loops engage the outer surfaces of the top and bottom lining-sheets 2.

"After the iinish-fabrics A have been applied, first at one side and then at the other side of the .mattress, the result is a wellstuffed mattress of pleasing appearance, uniform in its workmanship.

As shown in Fig. 4, the mattress presents half-rolls at the corners. That is, the portions of the rolls which show exteriorly are at the upper and lower portions of the boxing. On the other hand, the top and bottom finish-fabrics are unbroken in their contour, the result being to give a pin-cushion corner' effect, with nicely rounded corners for vthe top and bottom finish-fabrics.

The method renders it unnecessary to introduceany filling between the top and bottom lining-fabrics 2 and the top and bottom finish-fabrics A. However, it is optional with the maker. whether any filling shall be introduced between the top and bot'- tom lining-fabrics and the top and bottom finish-fabrics.

`In the modication shown in Fig.' 5, A2 designates a casing like that shown in Fig. 1, except that the boxing 1 is of endless form, and the top lining-fabric 2 is left unattached, except at one edge. This permits the filling B to be introduced through the open top of the casing. Thereafter, the casing may be closed; the edge-rolls may then be formed; and the top and bottom finish-fabrics may then be applied.

In the modification shown in Fig. 6, the construction is similar to the construction already described, except that the casing designated A3 is provided with a borderboxing 9 comprising an outer fabric 9, an adjacent lining fabric 9b, and a layer of cotton 9, all quilted together by lines of stitching 9d.

Thus, it will be noted that the lining-fabric in this instance is immediately adjacent the inner surface of the inish-fabrie In this case, the lining-fabric 9" of the boxing may have its margins sewed to the top and bottom lining-fabrics designated 2a; the corner stitching to form the edge-rolls may then be performed; and the top .and bottom finish-fabrics, also designated A, may be applied.

In the modification shown in Fig. 7, the

casing A4 is provided with a boxing desig- ,l

nated 10. This boxing is of the more usual form, comprising a finish-fabric l0, an adjacent layer of cotton 10b, and a lining fabric 10", all quilted together by stitchings 10d.

In this instance, the outer fabric 10 of the boxing is shown sewed to the top and bottom lining-fabrics, designated 21. After the stufling operation, the edge-rolls are formed in the manner previously described, after which the top and bottom fabrics A are applied and sewed to the edge-portions of the fabric 10.

In any case, it is unnecessary to cut the top and bottom lining-fabrics free from the finish-fabric of the boxing before sewing the top and bottom finish-fabrics of the mattress to the margin of the finish-fabric of the" boxing.

By reference to Figs. 6y and 7 it will be understood that, before applying the top and bottom finish-fabrics A, it would be possible to cut the top and bottom liningfabrics between the corner ties and the seams at the corners of the casing. However, this is unnecessary and it is preferred not to follow this course.

The process described enables a unit comprising a casing and a filling to be constructed in such manner that the casing will l be particularly well stuffed, and the edgerolls at the corners .to be well'formed in a facile manner, the outer ends of the loops of the ties forming the edge-rolls being accuratelyrregistered with desired pointslin the stitching which forms the quilting of the boxing; and the process enables the mattress to be finished in a uniform manner by applying the top and bottom finish-fabrics and rios unconnected with said ties and having sewing them evenly to the edge-portions of their edge-portions sewed to the edge-porthe boxing. The resultant construction is tions of the boxing.

one in which the mattress has inner and outer top and bottom fabrics, providing a durable structure. If desired, filling material B3 may be introduced atthe corner portions of the mattress between the top and I bottom lining-sheets and the top and bottom finishing-fabrics.

The foregoing detailed description has been given for clearness of understanding only, and no unnecessary limitations should be understood therefrom, but the appended claims should be construed as broadly as permissible, in view of the prior art.

What we regard as new, and desire to secure by Letters Patent, is:

1. In the manufacture of mattresses, the steps which comprise: forming a unit comprising top and bottom lining-sheets, a boxing sewed to the lining-sheets, and a filling interposed between said lining-sheets;

`stitching the corner-portions of the unit to form edge-rolls, the stitches extending through said boxing and through said 1ining-sheets; and applying top and -bottom finish-fabrics and sewlng their edge-portions i to the edge-portions of the boxing.

2. In the manufacture of a mattress,the method which comprises: `forming a casin comprising `a quilted boxing, and top an bottom lining-sheets; introducing a filling into the casing after the casing has been formed, but before it has been wholly closed; completing the closing of the casing; stitching edge-rolls through the corner-portions of the unit thus described; and applying top `and bottom finish-fabrics and sewing their edge-portions to the edge-portions of the boxing. A M

3. A mattress making process, comprising: sewing-to the edge-portions of the finishfabricvof a pre-formed boxing edge-portions of top and bottom 1ining-sheets to form a casing having an open end introducing into the casing a filling and closing the opening therein; forming corner edge-rolls on the l unit thus described by stitches which extend through the inish-fabric of. the boxing, the lining-sheets, and the interposed illing material; and applying top and bottom nishfabrics to the unit and sewing the edge-portions thereof to the edge-portions of the finish-fabric of the boxing.

4l A mattress comprising a unit which comprises a casing consisting of a boxing and lining-sheets united thereto, and a filling within the casing comprising a spring-structure and overlying and underlying layers of filling material; ties extending through the boxlng and through the lining-fabrics md formlng edge-rolls at the corner-portions of the unit; and top andbo'ttom finish-fab- SOLOMON KARPEN. FRANK KASPAR. 

